Reel assembly for winding web materials

ABSTRACT

A reel assembly includes a first hub defining an outer surface, a second hub co-axially disposed relative to the first hub, and a first movable member including a spooling surface that is movable to a position exterior to the outer surface to define at least a portion of an effective outer reel diameter of the assembly. The first and second hubs are manually rotatable relative to one another between a first rotational position and a second rotational position, the assembly being characterized by an expanded state in the first rotational position and a contracted state in the second rotational position where the effective outer reel diameter is greater in the expanded state than in the contracted state.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 60/803559, filed May 31, 2006, the disclosure of which is incorporated by reference herein in its entirety.

BACKGROUND

The production and use of web materials have been beneficially employed in a wide range of industrial and technical applications. Web materials include paper webs, fibrous webs, thin films and film laminates, and metal foils and sheets. Such web materials are commonly produced in widths up to several meters wide to take advantage of production economies of scale, but the production web materials are often slit down to a desired usable size of, for example, as small as a few centimeters in width. In this regard, the wider production web materials are typically slit down to size and rolled onto cores, resulting in a desired width of web material on a core that is suited for subsequent transportation and end use.

Cores useful in winding web materials include plastic cores, cardboard cores, and laminate cores, in general. The cores are typically slid over a winding mandrel, and optionally, an exterior surface of the core is prepared for gripping and winding web material. For example, some cardboard cores are provided with an adhesive coated onto a portion of the exterior surface. In this manner, the web material adheres to the exterior surface of the core and is prevented from sliding over the exterior surface of the core during winding. In any regard, the use of a core in winding web material adds an expense to the downstream processing of the web material.

Other winding processes employ a coreless mandrel that enables winding of web material directly onto the mandrel without the added expense of a core. Such mandrels typically are expandable to a winding configuration. The known expandable mandrels typically employ either fluid expandable bladders, or a collection of moving parts that are actuated to expand an outer surface of the mandrel to the winding configuration. In this regard, the greater the extent of the expansion of the outer surface of the mandrel, the greater the extent that the moving parts are displaced.

Web materials have become ubiquitous due to their wide range of beneficial applications across many industries. The manner in which the webs are wound and unwound can play an important role in the ultimate end use of the webs. To this end, improvements in the winding and unwinding of web materials will be beneficial to a wide variety of industries and welcomed by a wide variety of end users of web materials.

SUMMARY

The present application discloses, inter alia, a reel assembly for winding a material web. The reel assembly includes a first hub defining an outer surface, a second hub co-axially disposed relative to the first hub, and a first movable member movable to a position exterior to the outer surface to define at least a portion of an effective outer reel diameter of the assembly. In particular, the first hub defines the outer surface and an inner surface. The first movable member forms a spooling surface for receiving a material web and a bearing surface, and the spooling surface is movable to a position exterior to the outer surface to define at least a portion of an effective outer reel diameter of the assembly. The second hub includes an outer circumferential surface and a first transition zone defining a recess and a ramp, the ramp extending in a radially inward fashion from a first side that is contiguous with the circumferential surface to a second side that is opposite the first side. The first and second hubs are rotatable relative to one another between a first rotational position in which the bearing surface is proximate the first side of the ramp, and a second rotational position in which the bearing surface is proximate the second side of the ramp, and the assembly is characterized by an expanded state in the first rotational position and a contracted state in the second rotational position where the effective outer reel diameter is greater in the expanded state than in the contracted state.

The present application also describes a reel assembly for winding a material web. The reel assembly includes an outer hub, an inner hub, and a first moveable member having a spooling surface and a bearing surface. The outer hub includes an outer surface, an inner surface, and a first slot extending from the outer surface to the inner surface. The inner hub is rotatably mounted within the outer hub between at least a first and second rotational position, and is provided with a first recess. The first moveable member is mounted such that at least a portion thereof extends through the first slot, and such that in the first rotational position the inner hub contacts the bearing surface to maintain the spooling surface at an extended position, and in the second rotational position the first recess receives the bearing surface to move the spooling surface to a retracted position.

The present application also describes a method of processing a material web. The method includes providing a reel assembly manually operable to transition a spooling surface thereof between an expanded state and a contracted state, and transitioning the spooling surface to the expanded state. The reel assembly includes an inner hub co-axially disposed within an outer hub, where the inner hub defines a ramp and the outer hub defines an outer surface and a through-slot corresponding with the ramp. The method additionally includes winding the material web directly onto the spooling surface in the expanded state to form a wound web. The method further includes manually transitioning the spooling surface to the contracted state, and removing the wound web from the spooling surface.

The present application also describes a system for processing web material. The system includes a supply of web material, and the reel assembly described above, about which a length of web material from the supply is wound.

These and other aspects of the present application will be apparent from the detailed description below. In no event, however, should the above summaries be construed as limitations on the claimed subject matter, which subject matter is defined solely by the attached claims, as may be amended during prosecution.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to help describe the present invention. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate like parts.

FIG. 1 illustrates an exploded perspective view of a reel assembly;

FIG. 2A illustrates a perspective view of a first hub of the reel assembly;

FIG. 2B illustrates a cross-sectional view of the hub of FIG. 2A;

FIG. 3 illustrates a perspective view of a movable member of the reel assembly;

FIG. 4A illustrates a perspective view of a second hub of the reel assembly;

FIG. 4B illustrates a cross-sectional view of the hub of FIG. 4A;

FIG. 5A illustrates a top view of a flange of the reel assembly;

FIG. 5B illustrates a cross-sectional view of the flange of FIG. 5A;

FIG. 6 illustrates a top view of an end plate of the reel assembly;

FIG. 7 illustrates a cross-sectional view of a locking mechanism assembled to the end plate of FIG. 6;

FIG. 8 illustrates a perspective view of an assembled reel assembly;

FIG. 9A illustrates a cross-sectional view of the assembled reel assembly illustrated in FIG. 8 in a first rotational position where the reel assembly is in an expanded state;

FIG. 9B illustrates a cross-sectional view of the reel assembly of FIG. 8 including a web wrapped around expanded spooling surfaces of the assembly;

FIG. 9C illustrates a perspective view of a free body diagram of a movable member separate from other components the reel assembly illustrated in FIG. 9B;

FIG. 10 illustrates a cross-sectional view of the assembled reel assembly illustrated in FIG. 8 in a second rotational position where the reel assembly is in a contracted state;

FIGS. 11A-B illustrate a cross-sectional view of a portion of an alternative reel assembly in which moveable members are pivotably attached to an inner hub and have bearing surfaces that slide along a ramp in a recess formed in the outer hub, where FIG. 11A illustrates the alternative reel assembly in an expanded state and FIG. 11B illustrates the alternative reel assembly in a contracted state;

FIG. 12 illustrates a perspective view of a reel assembly employed in a system for processing web material;

FIG. 13A illustrates a cross-sectional view of another reel assembly in a first expanded rotational position; and

FIG. 13B illustrates a cross-sectional view of another reel assembly in a second contracted rotational position.

DETAILED DESCRIPTION

FIG. 1 illustrates an exploded perspective view of a reel assembly 20. The reel assembly 20 includes a first hub 22, a plurality of movable members 24 coupled to the first hub 22, a second hub 26 co-axially disposed relative to the first hub 22, a flange 28 and an end plate 30 coupled to opposing ends of the second hub 26, and a locking mechanism 32 coupled to the end plate 30 and the first hub 22.

The flange 28 and the end plate 30 can be coupled to the second hub 26 to define a substantially stationary “barrel” around which the first hub 22 rotates. The locking mechanism 32 includes a handle 34 that is coupled to the rotatable first hub 22, such that the handle 34 and the first hub 22 rotate relative to the substantially stationary barrel formed by the second hub 26 and the opposing flange 28 and end plate 30 (or vice-versa). In this manner, the locking mechanism 32 is movable between a locked position that maintains a fixed relative position between the first and second hubs 22, 26, and an unlocked position that permits the first hub 22 to rotate relative to the second hub 26 (or vice-versa).

In one embodiment, the first hub 22 is an outer hub, and the second hub 26 is an inner hub. The hubs 22, 26 are co-axially mounted relative to one another such that the outer hub 22 rotates around the inner hub 26 (and vice-versa) between a first rotational position in which the assembly 20 is in an expanded state, and a second rotational position in which the assembly 20 is in a contracted state. In particular, rotation of the outer hub 22 relative to the inner hub 26 actuates movement of the movable members 24. Rotation of the outer hub 22 from the first position relative to the inner hub 22 (i.e., the assembly 20 in the expanded state) to the second rotational position (i.e., the assembly 20 in the contracted state) is characterized by a radial inward movement of the movable members 24. In this manner, an effective outer reel diameter of the assembly 20 is greater in the expanded state as compared to the contracted state.

As employed herein, the term “diameter” is used broadly to refer to a maximum width of a body, whether or not the body is circular in shape. Thus, the term diameter is applicable to non-circular shapes. Non-circular bodies may also be characterized by an effective diameter, where the effective diameter is the circumference of the body (or the circumference of a path circumscribing the body, such as the path of a web wrapped tautly around the body as shown for example in FIG. 9B) divided by pi. The effective diameter is thus the diameter of a circle whose circumference is the same as the circumference of the body or of a path circumscribing the body. Of course, this definition also includes the case where the body or path is circular.

In an exemplary embodiment described in detail below, the locking mechanism 32 selectively locks the hubs 22, 26 in the first rotational position characterized by a relative maximum effective outer reel diameter that is suited for winding web material onto the reel assembly 20. Actuation of the locking mechanism 32 to the unlocked position permits the hubs 22, 26 to rotate relative to one another to the second rotational position characterized by a relative minimum effective outer reel diameter that is suited for removing the wound web material from the reel assembly 20.

FIG. 2A illustrates a perspective view of an exemplary embodiment of the first hub 22. The first hub 22 includes a first end 50, an opposing second end 52, an outer surface 54, an inner surface 56, and slots 58 a, 58 b, 58 c, 58 d extending from the outer surface 54 to the inner surface 56. In alternative embodiments, at least some of the slots 58 a-d can be omitted, or more slots can be added.

However, the hub 22 preferably includes at least one slot, for example, one of the slots 58 a-58 d. A movable member 24 (FIG. 1) is associated with each slot that is provided. In one embodiment, the movable members 24 are coupled to the outer surface 54 of the hub 22, and the hub 22 includes a hinge trough 60 and bores 62 a, 62 b that are configured to pivotally receive one of the movable members 24. As noted above, the number of slots 58 a-58 d corresponds to the number of movable members 24, such that the number of hinge troughs 60 equals the number of slots 58 a-58 d. Although FIG. 2A illustrates four slots 58 a-58 d, it is to be understood that the hub 22 can include from one to more than four slots, depending upon the application to which the assembly 20 is directed.

The second end 52 of the hub 22 can include a channel 64 sized and configured to receive a portion of the handle 34 (FIG. 1) of the locking mechanism 32. The channel 64 is preferably sized to slideably receive the handle 34 portion. In some cases, a width of the channel 64 along the circumference of the second end 52 is in a range from 0.2 to 0.4 inch (0.5 to 1.0 cm), preferably from 0.25 to 0.3 inch (0.6 to 0.8 cm), depending upon a selection of material for the handle 34, the size of the hub 22, and the application to which the assembly 20 is directed.

The hub 22 has a length L1 of any desired dimension. In some cases, L1 can be in a range from 3 to 4 inches (7.6 to 10.2 cm), e.g. about 3.4 inches (8.6 cm). In miniaturized applications, L1 can be 1 inch (2.54 cm) or less. In large industrial applications, L1 can be 4 inches (10.2 cm) or more.

FIG. 2B illustrates a cross-sectional view of the hub 22. As a point of reference in light of FIG. 2A, the slot 58 d is oriented in an up position relative to the illustration in FIG. 2B, and the view in FIG. 2B is directed from the first end 50 toward the second end 52. Preferably, the slots 58 a-58 d are through-slots, extending from the outer surface 54 to the inner surface 56. In some embodiments, each of the slots 58 a-58 d can have a width W in a range from 0.5 to 1.5 inches (1.3 to 3.8 cm), preferably about 1.0 inch (2.54 cm), although other suitable dimensions are also acceptable depending upon the design of the moveable members 24 and the application to which the assembly 20 is directed.

The hub 22 has an outside diameter D1 defined by the outer surfaces 54 and a wall thickness of T1 extending between the outer surface 54 and the inner surface 56 of the hub 22. Again, the term “diameter” is used broadly to refer to the width or cross-wise dimension of a body, whether or not the body is circular in shape. In one embodiment, the outside diameter D1 is in a range from 3 to 4 inches (7.6 to 10.2 cm), preferably about 3.75 inches (9.5 cm), although other sizes can of course be selected depending on the intended application for assembly 20. In one embodiment, the wall thickness T1 is in a range from 0.25 to 0.75 inches (0.63 to 1.9 cm), preferably about 0.5 inches (1.3 cm), but again other sizes are also acceptable based upon the materials selected for the hub 22 and the application to which the assembly 20 is directed. As illustrated in FIG. 2B, four slots 58 a-58 d are provided. Alternative embodiments may use other numbers of slots, whether one, two, three, or four or more. Where more than one slot is provided, the slots are preferably arranged to be substantially equally spaced along the periphery of the hub 22 as shown in FIGS. 2A-2B.

The hinge troughs 60 can extend from the outer surface 54 to the inner surface 56 and can be offset relative to a corresponding one of the slots 58 a-58 d. For example, the hinge trough 60 proximate slot 58 d can be offset from the slot 58 d by an angle A that ranges from 25 to 40 degrees, preferably about 30 degrees. In the embodiment shown, the four slots 58 a-58 d are separated from each other by approximately 90 degrees, and four corresponding hinge troughs 60 are provided, each hinge trough being offset from and associated with a respective one of the slots 58 a-58 d. Although the hinge troughs 60 are each shown as being oriented radially (i.e., parallel or roughly parallel to a radius of hub 22), they can also have other orientations. For example, each hinge trough 60 can be in-line with its associated (neighboring) slot 58 a-d.

The outer hub 22 is formed from suitable materials including, for example, metals such as aluminum or stainless steel, and plastics such as polyvinyl chloride (PVC), styrene including acrylonitrile butadiene styrene (ABS), thermoplastics such as polyethylene, nylon, or polyester, thermosets such as certain polyesters, rubbers, or epoxies, blends or compounds of such plastics, or other suitable reel assembly materials.

FIG. 3 illustrates a perspective view of an exemplary movable member 24. This member 24, which is capable of pivotal motion like a hinge, has a leading end 70 opposite a trailing end 72, as well as a spooling surface 74 (referenced generally) and a bearing surface 76.

In the illustrated embodiment, the leading end 70 is a curved portion of thin material, for example a shaped stainless steel plate, which undulates to define a curved segment, a prominent portion of which includes the spooling surface 74. The trailing end 72 defines a first ear 78 a opposite a second ear 78 b, and a hinge tab 80. The trailing end 72 is configured to pivotally couple to the first hub 22 (FIG. 2A). In this regard, one embodiment provides a bore 82 a in the first ear 78 a that is configured to align with the bore 62 a (FIG. 2A) of the first hub 22, and a bore 82 b in the second ear 78 b that is configured to align with the bore 62 b (FIG. 2A) of the first hub 22, and hinge tab 80 configured to be received by the hinge trough 60 (FIG. 2A). In this manner, the movable member 24 is coupleable to the first hub 22 at the trailing end 72, with the leading end 70 being free to move relative to the outer surface 54 (FIGS. 2A, 2B).

Other mechanisms can be used to pivotally couple the trailing end 72 to the outer surface 54 of the hub 22. For example, a continuously hinged edge can be used at the trailing end 72, or a living hinge can be used particularly where the movable member 24 (or at least the trailing end thereof) is formed of a flexible plastic.

In the illustrated embodiment, the spooling surface 74 is opposite the bearing surface 76, the spooling surface 74 being disposed at an uppermost extension of the member 24 and the bearing surface 76 being disposed at a lowermost extension thereof. Changing the geometry of the curvature adjacent the leading end 70 can change the distance between the spooling surface 74 and the bearing surface 76, which in turn can change an effective outer reel diameter of the assembly 20 (FIG. 1), as more fully described below.

Generally, the movable member 24 is formed from suitable materials including, for example, metals such as aluminum or stainless steel, and plastics such as PVC, styrene including ABS, thermoplastics such as polyethylene, nylon, or polyester, thermosets such as certain polyesters, rubbers, or epoxies, blends or compounds of such plastics, or other suitable reel assembly materials.

FIG. 4A illustrates a perspective view of the second hub 26 introduced in FIG. 1. The second hub 26 has a first end 100 opposite a second end 102, an outer circumferential surface 104 opposite an inner surface 106, and a plurality of transition zones 108 a, 108 b, 108 c, 108 d (transition zones 108 b and 108 c are obstructed from view). Each of the transition zones 108 a-108 d has a respective recess 116 a-116 d and a respective ramp 118 a-118 d (ramps 118 b and 118 c are obstructed from view).

In some cases, the hub 26 is an inner hub about which the first hub 22 (FIG. 2A) rotates (and vice-versa) between the first and second rotational positions as previously described. The second end 102 of the second hub 26 can include a detent 114 that is configured to align with the channel 64 (FIG. 2A) and receive a portion of the locking mechanism 32 (FIG. 1) when the hubs 22, 26 are selectively locked in the first rotational position.

Hub 26 has a length L2 which is preferably slightly greater than the length L1 of outer hub 22. In exemplary embodiments L2 can be in a range from 3 to 4 inches (7.6 to 10.2 cm), preferably about 3.56 inches (9.04 cm), but the reader will understand that other dimensions for the length L2 can also be selected. For example, in miniaturized applications, L2 may be less than 1 inch (2.54 cm), while in large industrial applications, L2 may be greater than 4 inches (10.2 cm).

FIG. 4B illustrates a cross-sectional view of the second hub 26. Relative to FIG. 4A, the cross-sectional view of FIG. 4B is directed from the first end 100 toward the second end 102. Each transition zone 108 a-108 d includes a respective recess 116 a-116 d and a respective ramp 118 a-118 d. In the illustrated embodiment, each of the recesses 116 a-116 d defines a passage through the second hub 26, and each of the ramps 118 a-118 d, for example the ramp 118 a, includes a ramp surface 120 that is contiguous with circumferential surface 104 and that extends radially inwardly, and a ramp tip 122. The ramp surface 120 can be straight or curved (whether uniformly curved or cammed) as desired.

Preferably, the ramp surface 120 joins the circumferential surface 104 smoothly rather than abruptly, the smooth junction being characterized by a radius R1. The transition zone 108 a thus transitions radially inward from circumferential surface 104 to the smooth junction coincident therewith of radius R1, to the ramp surface 120 and finally to the ramp tip 122. Ramp tip 122 can also be rounded.

The radius R1 of the ramp 118 a is continuous with the outer circumferential surface 104 and defines a location of maximum potential energy for objects moving along the transition zone 108 a, such as, for example, the bearing surface 76 of the movable member 24 (FIG. 3). In this regard, the ramp 118 a can be viewed as a potential energy surface where the potential energy of an object on the ramp 118 a is greater when proximate to the radius R1, and the potential energy is lower when the object moves toward the ramp tip 122. That is to say, absent other constraints (such as provided by the locking mechanism 32 of FIG. 1), objects positioned on the radius R1 are predisposed to move towards the ramp tip 122 to a lower energy state.

The second hub 26 has a diameter D2 less than diameter D1 of the first hub 22 (FIG. 2B), and preferably the second hub 26 is configured and sized to fit inside of first hub 22 in a co-axial arrangement such that the two hubs 22, 26 can rotate independently of each other. In an exemplary embodiment, D2 is in a range from 3 to 3.5 inches (7.6 to 8.9 cm), preferably about 3.25 inches (8.26 cm). The second hub 26 also has a wall thickness T2 extending between the circumferential surface 104 and the inner surface 106, which in exemplary embodiments is in a range from 0.25 to 0.75 inches (0.64 to 1.91 cm), preferably about 0.5 inches (1.27 cm).

The inner hub 26 is formed from suitable materials including, for example, metals such as aluminum or stainless steel, and plastics such as PVC, styrene including ABS, thermoplastics such as polyethylene, nylon, or polyester, thermosets such as certain polyesters, rubbers, or epoxies, blends or compounds of such plastics, or other suitable reel assembly materials.

FIG. 5A illustrates a top view of the flange 28 of the reel assembly 20. In an exemplary embodiment, the flange 28 is annular in shape, and includes an annular step 130 sized to receive the second, inner hub 26 (FIG. 1). With reference to FIG. 1, the flange 28 can be coupled to the inner hub 26 so as to form an end stop that keeps the inner hub 26 centered inside of the outer hub 22 while permitting relative rotation therebetween. To this end, the flange 28 can form one end of a “barrel” about which the hub 22 rotates. In an exemplary embodiment, flange 28 has a diameter D3 in a range from 3.75 inches to 4.2 inches (9.53 to 10.67 cm), and preferably about 4.0 inches (10.2 cm).

FIG. 5B illustrates a cross-sectional view of the flange 28. In an exemplary embodiment, the annular step 130 has a diameter that is approximately equal to diameter D2 of the second hub 26, such that the annular step 130 can receive the first end 100 of the second hub 26. The flange 28 is fastened or otherwise coupled to the second hub 26 by any known fastening mechanism, such as bolts, screws, weld joints, adhesives, or the like.

The flange 28 is formed from suitable materials including, for example, metals such as aluminum or stainless steel, and plastics such as PVC, styrene including ABS, thermoplastics such as polyethylene, nylon, or polyester, thermosets such as certain polyesters, rubbers, or epoxies, blends or compounds of such plastics, or other suitable reel assembly materials.

FIG. 6 illustrates a top view of the end plate 30 of the reel assembly 20. The end plate 30 has a notch 140 and a cover detent 142 formed within the notch 140, where the notch 140 is sized to slideably receive the locking mechanism 32 (FIG. 1).

The notch 140 can extend along an outer perimeter of the end plate 30 to define a port for receiving the locking mechanism 32 (FIG. 1) between the first rotational position and the second rotational position. In this regard, the notch 140 subtends an angle B along a perimeter arc length of the end plate 30, the angle B preferably falling in a range from 20 to 40 degrees, preferably about 30 degrees, although other are lengths are also acceptable.

In an exemplary embodiment, the end plate 30 is attached to the second hub 26 and defines a cover diameter that is selected to be approximately the same as diameter D1 of the first hub 22, or at least no greater than diameter D1. In this manner, when the assembly 20 (FIG. 1) is in the contracted state (e.g., the hubs 22, 26 in the second rotational position), wound web material can be removed from the assembly 20 by being slid off of the assembly 20 over the end plate 30. The end plate 30 can be attached to the second hub 26 by any known fastening mechanism, such as bolts, screws, weld joints, adhesives, or the like.

The notch 140 can be formed in the end plate 30 by any known means, whether by machining or otherwise removing material from an initially intact (fully circular) disk, or forming the end plate in the shape shown in FIG. 6 without any material removal steps. Preferably, a first portion 141 of the notch 140 has a radius that is sized to geometrically correspond to the radius (half of D2) of the second, inner hub 26. That is to say, when assembled, the first portion 141 of the notch 140 is aligned with the circumferential surface 104 of the second hub 26.

The end plate 30 includes the cover detent 142 that is relieved within the notch 140. When the end plate 30 is coupled to the second hub 26 (FIG. 4A), the cover detent 142 aligns with the detent 114 (FIG. 4A) formed in the second hub 26. The channel 64 formed in the first hub 22 (FIG. 2A) moves as the first hub 22 rotates relative to the second hub 26, such that the channel 64 is aligned with the detent 114 and the cover detent 142 when the locking mechanism 32 (FIG. 1) is maneuvered to rotate the hub(s) 22 and/or 26 to the first rotational position.

The end plate 30 is formed from suitable materials including, for example, metals such as aluminum or stainless steel, and plastics such as PVC, styrene including ABS, thermoplastics such as polyethylene, nylon, or polyester, thermosets such as certain polyesters, rubbers, or epoxies, blends or compounds of such plastics, or other suitable reel assembly materials.

FIG. 7 illustrates a cross-sectional view of the locking mechanism 32 assembled to the end plate 30. The locking mechanism 32 includes: the handle 34 having a tab 150; an offset shoulder screw 152; a boss 154 sized to receive the screw 152; and a spring 156 configured to bias the handle 34 relative to the screw 152. Although boss 154 and end plate 30 are shown in FIG. 7 as being separate pieces joined during the assembly of locking mechanism 32, it is to be understood that boss 154 and end plate 30 can instead be formed as a single piece. Referring to FIG. 6, when the locking mechanism 32 is assembled to the end plate 30, the tab 150 can move along the notch 140 between a locked position where the tab 150 is secured within the cover detent 142, to an unlocked position where the tab 150 is not secured within the cover detent 142 and is free to move along the first portion 141 of notch 140, for example, to a position opposite the cover detent 142.

When assembled, the shoulder screw 152 is threaded into the boss 154 to connect the handle 34 to the end plate 30 such that the handle 34 is able to rotate relative to the end plate 30. A clearance is provided between the handle 34 and the end plate 30 to permit such rotation. The spring 156 biases the handle 34 relative to the end plate 30 (and the notch 140) to force the tab 150 into secure engagement with the cover detent 142 when the handle 34 is in the locked position and the first and second hubs are in the first rotational position.

From this position, the operator can grasp the handle 34, manually pushing it first in a radially outward direction to compress the spring 156 and disengage the tab 150 from the cover detent 142, then manually rotating the handle clockwise so that the tab 150 travels along the first portion 141 of the notch 140 until the tab 150 reaches the end of the notch 140. During this rotation, the (outer) first hub 22 rotates in unison with the handle since the tab 150 of the handle slidably engages the channel 64 of hub 22 (see FIG. 8). When further clockwise rotation is no longer possible, i.e., the tab 150 reaches the end of the notch 140 and contacts the side wall of the notch, the first and second hubs are oriented in the second rotational position discussed above. To return the hubs to the first rotational position, the operator simply grasps the handle 34, manually turning it counter-clockwise until the tab 150 contacts the opposite side wall of the notch 140 (the side wall proximate the cover detent 142), whereupon the spring 156 forces the handle radially inward so that tab 150 again engages the cover detent 142. The reader will understand that the reel assembly can be easily modified to reverse the direction for turning the handle 34, such that transitioning the reel assembly from the first (expanded) rotational position to the second (contracted) rotational position requires a counterclockwise rotation of the handle, and transitioning the assembly from the second (contracted) position to the first (expanded) position requires a clockwise rotation of the handle.

In general, the handle 34 and the boss 154 are formed from suitable materials including, for example, metals such as aluminum or stainless steel, and plastics such as PVC, styrene including ABS, thermoplastics such as polyethylene, nylon, or polyester, thermosets such as certain polyesters, rubbers, or epoxies, blends or compounds of such plastics, or other suitable reel assembly materials.

FIG. 8 illustrates a perspective view of the reel assembly 20 upon final assembly. The flange 28 and the end plate 30 are coupled to the second (inner) hub 26 (FIGS. 1 and 4A) to form the barrel of the assembly 20 about which the first (outer) hub 22 rotates (it being understood that in other embodiments, the assembly 20 can be configured such that operation thereof entails rotation of the second hub 26 relative to the first hub 22). In this manner, the first hub 22 is co-axially disposed over the second hub 26 and is rotatably retained between the flange 28 and the end plate 30.

The handle 34 is coupled to the boss 154 (FIG. 7) such that both the handle 34 and the first hub 22 rotate relative to the end plate 30 and the second hub 26. In this regard, the tab 150 of the handle 34 is received within the channel 64 of the first hub 22, such that the handle 34 and the first hub 22 move in unison. As illustrated in FIG. 8, the tab 150 of the handle 34 is secured in the locked position such that the hubs 22, 26 are maintained in the first rotational position. In this position, the spooling surface 74 is offset away from (above) the outer surface 54 of the first hub 22 to define the expanded state of the assembly 20 in which the effective outer reel diameter thereof is increased or expanded (compared to the contracted state described below).

FIG. 9A illustrates a cross-sectional view of the assembled reel assembly 20 in the expanded state (e.g., the hubs 22, 26 in the first rotational position). The second hub 26 is co-axially disposed within the first hub 22, and the movable member 24 is pivotally coupled along the trailing end 72 to the first hub 22. The bearing surface 76 of the movable member 24 is positioned proximate the radius R1 and the first side 120 of the ramp 118 such that the spooling surface 74 is elevated away from the outer surface 54 of the first hub 22 to define an expanded outer reel diameter D_(max) of the assembly 20. (As a point of reference, the assembly 20 defines a contracted outer reel diameter D_(min) in the contracted state, with D_(min) being less than D_(max). Both the expanded state and the contracted state also have corresponding effective diameters, the effective diameter of the expanded state being no greater than D_(max) but being greater than the effective diameter of the contracted state, the latter effective diameter being no greater than D_(mim).) In operation, as web material is wound onto the spooling surface 74, the movable member 24 is supported along the bearing surface 76 by the outer circumferential surface 104 (FIG. 4B) of the second hub 26 such that the spooling surface 74 supports large loads associated with high winding tension of web materials.

As shown in FIG. 9A, the hubs 22, 26 are selectively locked in the first rotational position such that the bearing surface 76 is retained proximate the radius R1 but poised to slide radially inward along the ramp 118 from the first side 120 of the ramp 118 to the ramp tip 122. Thus, when in the first rotational position, the movable members 24 are positioned such that the outer reel diameter D_(max) defined by the spooling surface 74 (in the expanded state) is exterior to the outer surface 54 of the first hub 22.

In this manner, the spooling surfaces 74 of the plurality of moveable members 24 can combine to prevent winding of the material web onto the outer surface 54 of the first hub 22. With a sufficient number and suitable placement of moveable members, and where the reel assembly 20 is in the expanded state, the wound material web may extend from spooling surface 74 to spooling surface without contacting the outer surface 54 of the first hub 72.

The undulating shape of the movable member 24 adjacent the leading end 70 can be selectively sized such that the outer reel diameter D_(max) in the expanded state is significantly greater than the outer reel diameter D_(min) of the assembly 20 in the contracted state (e.g., D_(min) may nominally equal the diameter D1 of the first hub 22). For example, D_(max) can be in a range from 1% to 100% larger than D_(min). Preferably, D_(max) ranges from 20% to 60% larger than D_(min). For example, when D1 and D_(min) both equal about 3.75 inches (9.53 cm), D_(max) may be about 4.5 inches (11.43 cm), such that D_(max) is about 25% larger than D_(min). Note that the same ranges of 1 to 100% and 20 to 60% also apply to the effective reel diameters in the expanded and contracted states of the reel assembly.

The outer reel diameter D_(max) can be selectively sized to accommodate the elasticity of a web that is wound about the assembly 20. For example, for applications in which a web having low elasticity (for example a metal film/foil) is wound about the assembly 20, the outer reel diameter D_(max) can be selected to range from about 1% to 5% larger than D_(min). That is to say, substantially inelastic webs wound onto an expanded assembly 20 can be removed from the assembly 20 after it is transitioned to the contracted state (i.e., the hubs are rotated to the second rotation position e.g. as shown in FIG. 10) even when the expanded state reel diameter D_(max) is only slightly larger, e.g., 1 to 5% larger, than the contracted state reel diameter D_(min).

Conversely, for elastic, stretchy webs, the expanded state reel diameter D_(max) is more significantly larger, e.g., 5 to 100% larger, than the contracted state reel diameter D_(min). Elastic webs ordinarily stretch when wound onto a reel assembly, creating a static load directed radially inward. The static load is borne by the assembly during winding, but should be substantially released after winding to permit removal of the wound roll. This is done by transitioning the reel assembly from the expanded state to the contracted state, where the contracted state is sufficiently smaller than the expanded state (the diameter or effective diameter in the expanded state is sufficiently larger than that of the contracted state) so that the static load is substantially released.

FIG. 9B illustrates a cross-sectional view of the reel assembly 20 in the expanded state as in FIG. 9A, but also illustrates a web 158 wrapped tautly around the reel assembly. The plurality of movable members 24 prevent the material web 158 from contacting the outer surface 54 of the first hub 22. Furthermore, each of the spooling surfaces 74 includes a primary spooling surface 159 and a secondary spooling surface 160, with the primary spooling surface 159 extending a maximum radial distance from a center of the assembly 20 (and thus defining the expanded state outer reel diameter D_(max)). In this regard, “spooling surface” refers to a surface contacted by the web as it is wound (or “spooled”) around the reel, normally when the reel is in its expanded state. Note that one can modify the shape of the moveable members 24 so that only one spooling surface (e.g. primary spooling surface 159) is formed on each moveable member, or two or more discrete spooling surfaces are formed on each moveable member. Furthermore, if the shape of the moveable members does not prevent the web from contacting the outer surface 54 of the first hub 22, portions of such outer surface 54 may also become spooling surfaces. With the configuration of FIG. 9B, however, when the web 158 is wrapped onto the assembly 20, the spooling surfaces 159, 160 support the web 158 and define its winding path 161. In this manner, the web 158 contacts distinct spooling surfaces 159, 160 on each of the moveable members 24. Thus, the surface originally identified as spooling surface 74 can comprise two or more discrete, non-contiguous spooling surfaces, depending on the design or shape of the moveable members.

Preferably, each moveable member 24 is shaped and oriented on the hub such that, in the expanded state of the reel assembly, the section of the moveable member that bears the greatest static load of the web extends in a direction approximately parallel to the direction of such load for maximum stability and strength. Referring to FIGS. 9B and 9C, the direction of the static load of a tautly wound web 158 is approximately radially inward towards the center of rotation of the hubs 22, 26, and the section of each moveable member 24 that bears the greatest static load of the web (i.e., the section between the primary spooling surface 159 and the bearing surface 76) also extends approximately radially inward in the expanded state of the reel assembly.

The winding path 161 is not necessarily circular; in fact, it is usually not precisely circular. For example, as illustrated, the winding path 161 is non-circular and spans across the movable members 24 from the primary spooling surfaces 159 of one movable member 24 to the secondary spooling surface 160 of the circumferentially adjacent movable member 24. The circumference of the winding path 161 can be used to calculate an effective (expanded state) outer reel diameter by dividing the winding path circumference by pi. Thus, a circle whose diameter is the effective diameter has a circumference equal to the length of one circuit of the winding path 161.

Although four movable members 24 are illustrated, it is to be understood that even one movable member 24 can be provided, with the resultant assembly configured to provide an expanded state effective outer reel diameter that is from 1 to 100% or more, or 20 to 60%, larger than the contracted state effective outer reel diameter.

FIG. 9C illustrates a perspective view of a free body diagram of movable member 24 separate from other components of reel assembly 20. The movable member 24 is fixed to the first hub 22 by the ears 78 a, 78 b and the hinge tab 80. Although the member 24 is preferably composed of a metal or other suitable material having sufficient rigidity to support the static load of the wound web material without substantially deforming, the construction of the member 24 (e.g. a stamped metal plate or sheet that is curved or bent in one plane but flat or straight in an orthogonal plane) also preferably allows leading end 70 of the movable member 24 to flex and rotate a small amount in response to forces imparted by the web 158 (FIG. 9B). In this manner, the leading end 70 is responsive to winding forces and preferentially and automatically shifts relative to an axis of the reel assembly 20 to achieve automatic tracking of the web 158, as more fully described below. Movable member 24 includes a central longitudinal axis C, and a transverse axis T that is transversely aligned with the leading end 70. The reel assembly has an axis of rotation A (that is illustrated in FIG. 9C in free space, although it is to be understood that axis A coincides with the intersection of D1 and D2 as shown in FIG. 9B). When assembled as part of the reel assembly 20, movable member 24 is fixed to first hub 22 by the ears 78 a, 78 b such that the leading end 70 is cantilevered relative to the trailing end 72. To the extent the moveable member is capable of flexing, a first side 162 and an opposing second side 164 of the spooling surface 74 can translate and rotate relative to the fixed trailing end 72. Specifically, the sides 162, 164 can rotate about the central longitudinal axis C and translate relative to the first hub 22 to independently, automatically, and correctively adjust the orientation of transverse axis T of the leading end 70 relative to the reel assembly axis A in response to differential tension across the width of the web so that as the web is wound it remains centered on the reel assembly rather than telescoping away from the reel assembly.

Winding forces delivered from the web 158 (FIG. 9B) to the movable member 24 can be unbalanced and can potentially lead to a cumulative imbalance in the winding of the web 158. However, the movable member 24 is responsive to such imbalances in web 158 windings and provides an automatic tracking feature whereby each side 162, 164 is free to move independently relative to the outer hub 22 and automatically adjust the orientation of the leading end 70 such that the transverse axis T responsively adjusts (e.g. aligns) relative to reel assembly axis A.

During winding of the web 158, variations in the thickness of the web 158 and variations in other forces external to the web 158, can result in an imbalance in the lateral tracking of the web 158 along spooling surface 74. Without wishing to be bound by theory, it is believed that the cantilevered leading end 70 of the movable member 24 rotates and translates during winding to accommodate the unbalanced forces and correct possible variations in lateral tracking of the web 158 relative to the spooling surface 74.

For example, referring to FIGS. 9A-C, if a winding force of the web 158 material is imbalanced such that the winding force is greater on side 162 and less on side 164, side 162 flexes downward (i.e., that side of the bearing surface 76 moves slightly down the ramp 118). Thus, side 164 becomes elevated relative to 162, and the transverse axis T becomes misaligned with the reel assembly axis A. Such a canted position, which would normally be considered unstable, accommodates the imbalanced forces in the web and keeps the web centered on the reel assembly as it is wound. Thereafter, if the winding forces become balanced across the web or if they become imbalanced in an opposite sense (greater winding force on side 164 and less on side 162), the leading end 70 can translate and rotate in response to the changing forces to reorient the transverse axis T with respect to the reel assembly axis A. Thus, the design of the moveable member 24, allowing it to flex slightly in response to imbalanced or changing cross-web forces or tension, acts as a kind of “independent suspension” to allow the transverse axis of the spooling surface to reorient relative to the reel axis A in response to the imbalanced or changing forces in order to keep the web centered on the reel assembly during winding.

Note that the configuration of the moveable members to provide the automatic tracking feature can be adapted for use on a wide variety of reel assemblies, including reel assemblies that may have only one hub, and reel assemblies of otherwise conventional design.

FIG. 10 illustrates a cross-sectional view of the hubs 22, 26 in the second rotational position, such that the reel assembly 20 is in the contracted or retracted state. In the contracted state, the movable member(s) 24 have pivoted such that the spooling surface(s) 74 are retracted (relative to a spatial position in the expanded state), and the assembly 20 is characterized by an outer reel diameter D_(min) that is approximately equal to D1, the diameter of the first hub 22. In transitioning from the expanded state to the contracted state, the first and second hubs 22, 26 have been manually rotated relative to one another by movement of the handle 34 (FIG. 8). That is, the hubs 22, 26 have rotated from the first rotational position (FIGS. 9A, 9B) in which the bearing surface 76 is proximate the first side 120 of the ramp 118, to the second rotational position in which the bearing surface 76 is received by the recess 116.

In translating from the first rotational position to the second rotational position, the first hub 22 has rotated in the direction of arrow 170 relative to the second hub 26 such that the bearing surface 76 of the movable member 24 has moved down the ramp 118 radially inwardly from the first side 120 of the ramp 118 past the ramp tip 122 and received by the passage 116 such that the spooling surface 74 has retracted inwardly, and the assembly 20 occupies the contracted state.

The bearing surface 76 in the expanded state is preferably positioned at a relative maximum potential energy location proximate the first side 120 of the ramp 118. Consequently, the movable member 24 is naturally pre-disposed to move to a position associated with a lower potential energy position, such as is achieved when the bearing surface 76 moves to a location proximate the ramp tip 122. This state of quasi-equilibrium in the expanded state is accentuated by the inward compressive force that is exerted by wound web material wrapped around the spooling surfaces 74.

Thereafter, when the operator wants to removed the wound web material, he or she can manually rotate the hubs 22, 26 via the handle 34 such that the assembly 20 transitions to the contracted state of FIG. 10. As described above, when web material is wrapped onto the spooling surfaces 74, the assembly 20 is pre-disposed to transition to the contracted state of FIG. 10. In this contracted state, the spooling surface 74 is preferably retracted inwardly such that the outer reel diameter D_(min) or effective outer reel diameter is reduced to be approximately equal to D1, the diameter of the outer hub 22, so that the wound web material can be conveniently removed from the contracted assembly 20.

In alternative reel assemblies, the role of the first and second hubs can be at least partially reversed compared to those described above. For example, if suitably sized slots are provided in the outer hub, the moveable members can extend through such slots so that the trailing edge pivotably attaches to the inner hub. Further, a recess and ramp can be provided in the outer hub for each moveable member, and the bearing surface of the moveable member (proximate the leading edge thereof) can engage the recess, sliding along the ramp as the hubs are rotated relative to each other, forcing the spooling surface of each moveable member radially outward or inward to produce the expanded or contracted states (respectively) of the alternative reel assembly. FIG. 11A illustrates an alternative reel assembly in an expanded state, and FIG. 11B illustrates the alternative reel assembly in a contracted state.

FIG. 12 illustrates a perspective view of a system for processing web material. The system 200 includes an unwind spindle 202 rotatably maintaining a supply 204 of web material, a separation station 206, and reel assemblies 20 a and 20 b rotatably maintained downstream from the supply 204 of web material. In alternative embodiments, only one of the assemblies 20 a, 20 b can be employed, for example assembly 20 a, or more than two assemblies can be employed.

The unwind spindle 202 receives a wound roll of laminate web supply 204, the separation station 206 separates the laminate of web supply 204 into a desired output product and one or more remaining carrier (or waste) webs, and the reel assembly 20 winds the carrier/waste web(s) for subsequent disposal or reuse. In some cases, two carrier/waste webs are provided with the laminate of web supply 204, and two reel assemblies 20 a and 20 b are employed to wind the two waste webs exiting the separation station 206, as described below. In other embodiments, only one of the reel assemblies 20 a and 20 b is provided to wind one waste web, although it is to be understood that more than two reel assemblies can be beneficially employed when more than two waste webs are to be wound up.

The unwind spindle 202 is generally located upstream from the separation station 206, and upstream from the reel assembly/assemblies 20. In one embodiment, the unwind spindle 202 is driven by a motor (not shown) that is controlled by a control panel 207. Alternatively, the unwind spindle 202 and the reel assembly/assemblies 20 are each driven by a motor controlled by the control panel 207. Any differential rotation of the unwind spindle 202 relative to the reel assembly/assemblies 20 may create a wind-up tension in the waste webs wound onto the reel assembly/assemblies 20.

Since waste webs are often subsequently disposed of or recycled, it may be desirable to wind the waste webs into tightly compressed rolls to minimize their size. The wind-up tension delivered onto the reel assembly/assemblies 20 can be significant, and in the case of the waste webs being polymeric film material, the wind-up tension can be in a range from 1 pound per lineal inch (pli) (0.18 kg per lineal cm), in applications where the waste web is allowed to “float” on assembly 20 with minimal tensioning, to 50 pli or more. Consequently, the compressive force directed radially inward to the wound roll ranges from several pounds force to several hundred pounds force. For example, the illustrated reel assembly 20 that is provided with four stainless steel movable members 24 bears about 400 pounds of compressive force when winding some film-based waste webs, and this compressive force is spread across the four movable members 24.

The supply 204 of web material includes a backing layer 210, a cover layer 212, and output product in the form of a plurality of film strips 214. However, in some applications the cover layer 212 is optional. During use, the unwind spindle 202 unwinds the supply 204 of web material and the separation station 206 separates the plurality of film strips 214 from the backing layer 210 and the cover layer 212. The reel assembles 20 a and 20 b operate to wind the waste/excess backing layer 210 and the cover layer 212 into coreless waste rolls.

In an exemplary process of winding web material, the control panel 207 receives input data and drives the unwind spindle 202 to direct the supply 204 of web material into the separation station 206. The separation station 206 separates the plurality of useable film strips 214 from the backing layer 210 and the cover layer 212. Relative to FIG. 12, the reel assembly 20 a winds the waste backing layer 210 about the expanded spooling surface 74 and the reel assembly 20 b winds the waste cover layer 212 about a corresponding expanded spooling surface 74. As noted above, the waste layers 210, 212 can be wound onto the reel assemblies 20 a, 20 b with a significant level of wind-up tension. Such tightly wound waste rolls of layers 210, 212 can potentially collapse plastic and/or fiber board cores.

In contrast, each of the reel assemblies 20 a, 20 b is constructed to withstand the high wind-up tensions, even when the web is exclusively supported (in the expanded state of the reel assemblies) by the spooling surface(s) of the moveable member(s) and spaced apart from the outer surface of the respective outer hubs. Upon completion of separating the desired number of strips 214 off of the web supply 204, the reel assemblies are manually transitionable to a contracted state where the outer reel diameter D_(min) is substantially smaller than the diameter D_(max) in the expanded state, and D_(min) may if desired approximately equal the diameter of the outer hub, D1 The wound waste layer 210, 212 material can then be conveniently removed and disposed of.

FIG. 13A illustrates a cross-sectional view of another reel assembly 300 in a first expanded rotational position. The reel assembly 300 includes a first hub 302, a second hub 304 co-axially disposed relative to the first hub 302, and a first movable member 306 disposed between the first hub 302 and the second hub 304.

The first hub 302 is an outer hub having an outer surface 308, an inner surface 310, and a first slot 312 extending from the outer surface 308 to the inner surface 310.

The second hub 304 is an inner hub co-axially disposed within the first hub 302 and having an outer circumferential surface 314 and a transition zone 316. The transition zone 316 includes a recess 318 and a ramp 320, where the ramp 320 extends in a radially inward fashion from a first side 322 that is contiguous with the circumferential surface 314 to a second side 324. Preferably, the ramp 320 joins circumferential surface 314 smoothly rather than abruptly. The transition zone 316 thus transitions radially inward from circumferential surface 314 smoothly over the ramp 320 to the second side 324 adjacent to a minima 326 of the recess 318.

A plurality of movable members 306 can be disposed in a plurality of corresponding slots 312 such that the movable members 306 associate with a plurality of transition zones 316 formed in the second hub 304. Alternative embodiments may use one, two, three, or four or more movable member(s) 306 and corresponding slot(s) 312. When more than one slot 312 is provided, the slots are preferably arranged to be substantially equally spaced along a periphery of the hub 302.

The movable member 306 has a spooling surface 330 opposite a bearing surface 332. FIG. 13A illustrates the reel assembly 300 in an expanded state in which the spooling surface 330 defines an outer reel diameter or effective diameter that is greater than a diameter DD of the reel assembly 300 extending between opposing outer surfaces 308 of the outer hub 302.

For example, diameter DD transects a center of the first hub 302 and extends to opposing outer surfaces 308 of the first hub 302. The spooling surface 330 extends beyond the diameter DD and the outer surface 308 of the first hub 302 by a distance H. In the expanded state, the bearing surface 332 of the movable member 306 contacts the first side 322 of the ramp 320 such that the spooling surface 330 projects out of the slot 312 by the distance H to a position exterior to (i.e., beyond) the outer surface 308. In this manner, the extended movable member 306 defines an outer reel diameter of the assembly 300 that is greater than the diameter DD of the first hub 302 by the distance H. If an identical moveable member 306 is disposed on an opposite side of the reel assembly 300, the two moveable members define an expanded state outer reel diameter that is greater than the diameter DD by 2H. Depending on the number of moveable members 306 distributed around the reel assembly 300, the effective diameter of the reel assembly 300 in its expanded state is greater than the diameter DD by an amount that will not exceed 2H. For example, a sufficient number of moveable members 306 can be provided and distributed around the periphery of the reel assembly 300 so that the spooling surfaces 330 of the movable members 306 combine to prevent the material web from contacting the outer surface 308 of the first hub 302.

FIG. 13B illustrates a cross-sectional view of the reel assembly 300 in a second, contracted state. The outer hub 302 has been rotated in the direction of arrow 340 relative to the inner hub. The bearing surface 332 of the movable member 306 has translated down the ramp 320 from the first side 322 down to the minima 326 of the recess 318. Preferably, in transitioning from the expanded state to the contracted state, the movable member 306 retracts into the recess 318 by a distance of about H such that the spooling surface 330 is flush with or even retracted relative to the outer surface 308 of the outer hub 302.

In the contracted state illustrated in FIG. 13B, the bearing surface 332 is proximate the minima 326 of the recess 318 such that the movable member 306 is almost flush with the outer surface 308. In this manner, the outer reel diameter and effective outer reel diameter of the assembly 300 in the contracted state is approximately equal to the outer diameter DD of the outer hub 302. Thus, the outer reel diameter of the assembly 300 is greater in the expanded state illustrated in FIG. 13A than in the contracted state illustrated in FIG. 13B.

Various reel assemblies have been described herein that provide a coreless reel assembly including a first hub and a second hub co-axially disposed relative to the first hub, where the first and second hubs are manually rotatable relative to one another between a first rotational position and a second rotational position. The reel assemblies also include one or more movable members that define an outer reel diameter (including an effective outer reel diameter) and that shift between an expanded state in the first rotational position and a contracted state in the second rotational position, the outer reel diameter being greater in the expanded state than in the contracted state.

The reel assemblies can be constructed to withstand the high-compression winding of waste rolls of web material directly onto a spooling surface of the reel assemblies. In the manner described above, the spooling surface(s) are collapsible to the contracted state in the second rotational position to enable easy removal of the rolls of material web by sliding the rolls off of the coreless reel assemblies.

In addition, the reel assemblies can include movable members designed to flex and otherwise move to accommodate even tracking of web material wound onto spooling surfaces of the movable members. Consequently, web materials wound onto the spooling surfaces wind-up uniformly without skewing or telescoping.

The spooling surfaces of the movable members can, if desired, be retractable without the need for spring-loaded moving spooling surfaces that may be susceptible to tangling with web materials.

Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof. 

1. A reel assembly for winding a material web, comprising: an outer hub having an outer surface, an inner surface, and a first slot extending from the outer surface to the inner surface; an inner hub rotatably mounted within the outer hub between at least a first and second rotational position, the inner hub having a first recess therein; and a first moveable member having a spooling surface and a bearing surface; wherein the first moveable member is mounted such that at least a portion thereof extends through the first slot, and such that in the first rotational position the inner hub contacts the bearing surface to maintain the spooling surface at an extended position, and in the second rotational position the first recess receives the bearing surface to move the spooling surface to a retracted position.
 2. The assembly of claim 1, wherein the first recess includes a ramp surface.
 3. The assembly of claim 2, wherein the bearing surface slides along the ramp surface as the inner and outer hubs are rotated from the first rotational position to the second rotational position.
 4. The assembly of claim 1, wherein the first recess includes a through-slot in the inner hub.
 5. The assembly of claim 4, wherein the bearing surface extends through the through-slot in the second rotational position.
 6. The assembly of claim 1, wherein the inner hub has a wall thickness, and wherein the extended and retracted positions of the spooling surface define a distance greater than the wall thickness.
 7. The assembly of claim 1, wherein the first moveable member has a leading end proximate the spooling surface and a trailing end pivotally coupled to the outer hub.
 8. The assembly of claim 1, wherein the first slot is one of a plurality of slots extending from the outer surface to the inner surface, and wherein the first recess is one of a plurality of recesses in the inner hub, and wherein the first moveable member is one of a plurality of moveable members each having a spooling surface and a bearing surface.
 9. The assembly of claim 8, wherein the plurality of slots are substantially equally spaced around a circumference of the outer hub, and wherein the plurality of recesses are substantially equally spaced around a circumference of the inner hub.
 10. The assembly of claim 8, wherein the spooling surfaces are each maintained at extended positions in the first rotational position and each move to retracted positions in the second rotational position, and wherein the spooling surfaces in the extended positions produce a maximum effective diameter of the reel assembly, and the spooling surfaces in the retracted positions produce a minimum effective diameter of the reel assembly.
 11. A reel assembly for winding a material web, the reel assembly comprising: a first hub having an outer surface and an inner surface; a first movable member forming a spooling surface for receiving a material web and a bearing surface, the spooling surface movable to a position exterior to the outer surface to define an outer reel diameter of the assembly; and a second hub co-axially disposed relative to the first hub, the second hub including an outer circumferential surface and a first transition zone defining a recess and a ramp, the ramp extending radially inward from a first side to a second side opposite the first side; wherein the first and second hubs are manually rotatable relative to one another between a first rotational position in which the bearing surface is proximate the first side of the ramp, and a second rotational position in which the bearing surface is proximate the second side, the assembly characterized by an expanded state in the first rotational position and a contracted state in the second rotational position, the outer reel diameter being greater in the expanded state than in the contracted state.
 12. The reel assembly of claim 11, further comprising: a plurality of hinged members respective ones of which are pivotally coupled to the first hub adjacent a respective one of a plurality of slots; and a plurality of transition zones defined by the second hub that correspond with the plurality of hinged members.
 13. The reel assembly of claim 12, wherein the reel assembly is configured such that in the expanded state, the spooling surfaces of the plurality of hinged members combine to prevent winding of the material web onto the outer surface of the first hub.
 14. The reel assembly of claim 12, wherein each of the plurality of hinged members defines a spooling surface exterior the outer surface of the first hub.
 15. The reel assembly of claim 12, wherein the reel assembly is configured such that in the expanded state, a web wound tautly around the reel assembly contacts the spooling surfaces without contacting the outer surface of the first hub.
 16. The reel assembly of claim 11, wherein the first side of the ramp defines a radius coincident with the circumferential surface, and further wherein the bearing surface abuts the radius in the first rotational position.
 17. The reel assembly of claim 11, further comprising: a locking mechanism coupled to the first and second hubs for releasably locking the reel assembly in the first rotational position; wherein the locking mechanism includes a handle defining a tab, the tab movably received within a channel formed in an end of the first hub and the handle movably coupled to an end plate that is coupled to the second hub.
 18. The reel assembly of claim 17, wherein the second hub defines a detent sized to receive the tab, the handle biased relative to the end plate tab such that the tab is secured within the detent in the first rotational position.
 19. A system for processing web material, the system comprising: a supply of web material; and the reel assembly of claim
 1. 20. The system of claim 19, wherein the supply of web material includes a backing layer maintaining a plurality of film strips, the system further comprising: an unwind spindle rotatably maintaining the supply of web material upstream of the reel assembly; and a separation station located between the unwind spindle and the reel assembly, the separation station adapted to separate the film strips from the backing layer; wherein the reel assembly is operable to wind the backing layer into a coreless roll of waste web following processing of the web material at the separation station.
 21. A method of processing a material web, the method comprising: providing a reel assembly manually operable to transition a spooling surface thereof between an expanded state and a contracted state, the reel assembly including an inner hub co-axially disposed within an outer hub, the inner hub defining a ramp and the outer hub defining an outer surface and a through-slot corresponding with the ramp; transitioning the spooling surface to the expanded state; winding the material web directly onto the spooling surface in the expanded state to form a wound web; manually transitioning the spooling surface to the contracted state; and removing the wound web from the spooling surface.
 22. The method of claim 21, wherein the wound web is characterized by the absence of a separate core.
 23. The method of claim 21, wherein transitioning the spooling surface to the expanded state includes rotating the outer hub relative to the inner hub and moving a portion of a movable member up the ramp of the inner hub and through the through-slot such that the spooling surface extends beyond the outer surface of the outer hub.
 24. The method of claim 21, wherein manually transitioning the spooling surface to the contracted state includes rotating the outer hub relative to the inner hub and moving a portion of a movable member down the ramp of the inner hub and through the through-slot such that the spooling surface retracts relative to the outer surface of the outer hub. 